Arctic Cat DVX 250 2007 Service Manual
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Arctic Cat DVX 250 2007 Service Manual

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For Arctic Cat Discount Parts Call 606-678-9623 or 606-561-4983
FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2007 Arctic
Cat ATV 250 models. This manual is designed to aid service personnel in service-oriented applications.
This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to the
standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual
as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition.
The service technician should become familiar with the operation and construction of each component or system by
carefully studying this manual. This manual will assist the service technician in becoming more aware of and efficient
with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to emphasize
important information. The symbol ! WARNING identifies personal safety-related information. Be sure to fol-
low the directive because it deals with the possibility of severe personal injury or even death. The symbol
! CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the directive because it
deals with the possibility of damaging part or parts of the ATV. The symbol
mation worthy of particular attention. The symbol
cific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs
used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic
Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2006 Arctic Cat Inc.
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
AT THIS POINT directs the technician to certain and spe-
Back to TOC
www.mymowerparts.com
NOTE: identifies supplementary infor-
August 2006

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  • Page 1 Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information. The symbol ! WARNING identifies personal safety-related information. Be sure to fol- low the directive because it deals with the possibility of severe personal injury or even death.
  • Page 2 TABLE OF CONTENTS Foreword Click on the red text to go. General Information Periodic Maintenance/Tune-Up 3. Engine/Transmission Fuel/Lubrication/Cooling Electrical System Drive System Suspension 8. Steering/Frame 2007 2007 Controls/Indicators 10. Aids for Maintenance 250 ATV 250 ATV Utility 11. Troubleshooting Service Manual Service Manual...

  • Page 3: Table Of Contents

    SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS General Specifications (DVX Model) ....... 1-2 General Specifications (Utility Model) ..... 1-3 Break-In Procedure ..........1-4 Gasoline - Oil - Lubricant ........1-4 Genuine Parts ............1-5 Preparation For Storage.......... 1-6 Preparation After Storage........1-6 Back to TOC...

  • Page 4: General Specifications (Dvx Model)

    General Specifications* (DVX Model) CARBURETOR CHASSIS Type Keihin PTG-22 Dry Weight (approx) 186 kg (410 lb) Main Jet Length (overall) 168.3 cm (66.25 in.) Slow Jet Height (overall) 114.9 cm (45.25 in.) Pilot Screw Setting (turns) 1 1/2 Width (overall) 106.0 cm (41.75 in.) Jet Needle NBSD-3...

  • Page 5: General Specifications (Utility Model)

    General Specifications* (Utility Model) CARBURETOR CHASSIS Type Keihin PTG-22 Dry Weight (approx) 216 kg (477 lb) Main Jet Length (overall) 187 cm (73.6 in.) Slow Jet Height (overall) 111.8 cm (44.0 in.) Pilot Screw Setting (turns) 1 1/2 Width (overall) 105.1 cm (41.40 in.) Jet Needle NBSD-3...

  • Page 6: Break-In Procedure

    ! CAUTION burnished. Slow disc-speed hydraulic brakes must be properly burnished in order to achieve maximum Do not use white gas. Only Arctic Cat approved stopping power. gasoline additives should be used. ! CAUTION...

  • Page 7: Genuine Parts

    80W-90 hypoid. This lubricant meets all the lubrica- Tighten the gas tank cap securely after filling the tion requirements of the Arctic Cat ATV front dif- tank. ferentials and rear drives. ! WARNING ! CAUTION Do not over-fill the gas tank.

  • Page 8: Preparation For Storage

    Start the engine and ing it will assure many miles and hours of trouble- allow it to idle; then using Arctic Cat Engine free riding. Arctic Cat recommends the following Storage Preserver, rapidly inject the preserver procedure to prepare the ATV.
  • Page 9 8. Tighten all nuts, bolts, cap screws, and screws 10. Make sure the steering moves freely and does making sure all calibrated nuts, cap screws, and not bind. bolts are tightened to specifications. 11. Check the spark plug. Clean or replace as neces- 9.
  • Page 10 SECTION 2 - PERIODIC MAINTENANCE/TUNE-UP TABLE OF CONTENTS Periodic Maintenance Chart........2-2 Lubrication Points............ 2-3 Battery..............2-3 Fuses ..............2-4 Air Filter..............2-4 Valve/Tappet Clearance .......... 2-5 Testing Engine Compression ........2-5 Spark Plug............... 2-6 Muffler/Spark Arrester ..........2-6 Gas/Vent Hoses ............2-7 Adjusting Throttle Cable ..........

  • Page 11: Periodic Maintenance Chart

    A = Adjust I = Inspect Periodic Maintenance C = Clean L = Lubricate Chart D = Drain R = Replace Initial Service Every Month Every 3 Every 6 Every Year After Break-In Every Months or Months or Item or Every (First Mo or Every 100 Every 300...

  • Page 12: Lubrication Points

    To remove/charge the battery, use the following pro- cedure. Lubrication Points 1. Remove the seat. On the DVX model, remove the battery hold-down strap. On the Utility model, remove the battery box cover from the It is advisable to lubricate certain components peri- rear of the ATV;...

  • Page 13: Fuses

    NOTE: Foam Filter Cleaner and Foam Filter Oil Air Filter are available from Arctic Cat. 5. Dry the filter. The air filter inside the air filter housing must be 6. Put the filter in a plastic bag; then pour in air fil- kept clean to provide good engine power and gas ter oil and work the filter.

  • Page 14: Valve/Tappet Clearance

    CHECKING/DRAINING DRAIN TUBE 6. While holding the valve adjuster handle in place, rotate the valve adjuster dial counter- Periodically check the drain tube for gasoline or oil clockwise until proper valve/tappet clearance is accumulation. If noticed, remove the drain tube cap attained.

  • Page 15: Spark Plug

    4. Attach the Compression Gauge (p/n 0644-376). ! CAUTION NOTE: The engine must be warm and the battery Before removing the spark plug, make sure to clean must be fully charged for this test. the area around the spark plug. Dirt could enter 5.

  • Page 16: Gas/Vent Hoses

    2. Using a soft wire brush, clean the carbon from 2. Turn the adjuster until the throttle cable has the screen (3) taking care not to tear or damage proper free-play of 1-4 mm (1/16-3/16 in.) at the the screen. lever.

  • Page 17: Engine Oil - Filter

    6. Remove the oil fill plug and pour in 1.6 L (1.7 U.S. qt) of the recommended oil into the fill Engine Oil - Filter hole; then install the oil fill plug. ! CAUTION Replace the engine oil and oil filter at the scheduled intervals.

  • Page 18: Transmission Lubricant

    1. Place the ATV on level ground. 2. Loosen the fill plug; then remove the transmis- sion drain plug and drain the transmission lubri- cant. KM131A 2. If low, add SAE approved 80W-90 hypoid gear lube as necessary. To change the lubricant, use the following proce- dure.
  • Page 19 INSPECTING Inspect the drive chain for any of the following con- ditions. A. Loose pins. B. Loose or cracked rollers. C. Dry or rusted links. D. Kinked or binding links. E. Excessive wear. KM157A 2. Install an appropriate pin through the axle hub The presence of any of the conditions requires drive and rear sprocket.

  • Page 20: Tires

    Tires Driveshaft/Coupling (Utility Model) TIRE SIZES The following drive system components should be inspected periodically to ensure proper operation. The ATV is equipped with low-pressure tubeless tires of the size and type listed (see appropriate Specifica- A. Spline lateral movement (slop). tions in Section 1).

  • Page 21: Ignition Timing

    2. Using care not to bend or deform the spring clip, release the two ends of the spring clip from the Ignition Timing light housing; then remove the bulb from the headlight housing. The ignition timing cannot be adjusted; however, verifying ignition timing can aid in troubleshooting other components.

  • Page 22: Shift Lever

    D. Hi/Lo switch — headlight high beam or low ADJUSTING SHIFT LEVER beam will illuminate. 1. Place the shift lever in the N (neutral) position; E. Brake switches — rear brakelight will illumi- then set the engine stop switch to the STOP nate.

  • Page 23: Electrical Connections

    3. To bleed the brake system, use the following procedure. Electrical Connections A. Remove the cover and fill the reservoir with DOT 4 Brake Fluid. The electrical connections should be checked peri- B. Install and secure the cover; then slowly odically for proper function.
  • Page 24 CHECKING/REPLACING FRONT PADS The clearance between the brake pads and brake discs is adjusted automatically as the brake pads wear. The only maintenance that is required is replacement of the brake pads when they show excessive wear. Check the thickness of each of the brake pads as follows.

  • Page 25: Auxiliary/Rear Hydraulic Brake

    Auxiliary/Rear Hydraulic Brake CHECKING 1. With the engine off, the transmission in neutral, and the reverse lever in the forward position, press the brake pedal and attempt to move the ATV. KM267 2. If the rear wheels are locked, it is functioning properly.
  • Page 26 2. Remove the brake spring plate; then remove the NOTE: Whenever installing new pads, the new brake pads. pads must be burnished (see Burnishing Brake Pads in this section). Inspecting and Measuring MEASURING/REPLACING 1. Inspect the pads for gouges, chips, or wear. REAR/AUXILIARY BRAKE PADS (DVX Model) 2.

  • Page 27: Burnishing Brake Pads

    2. Remove the front and rear V-belt housing cool- ing ducts. When filling the cooling system, use pre-mixed Arctic Cat Antifreeze. While the cooling system is 3. Remove the cap screws securing the V-belt cover being filled, air pockets may develop; therefore, run...
  • Page 28 KM253 KM276 4. Remove the nut securing the movable drive 3. Install the movable drive face onto the crank- face; then remove the face. Account for the shaft making sure to “bottom” the sheave out stepped washer and spacer. against the center bushing. The crankshaft splines should be visible and the stepped washer should sit over the splines.
  • Page 29 5. Install the recoil starter and footwell assembly (Utility model). Tighten all hardware securely. KM252A Back 2-20 Back to TOC Back to Section TOC...
  • Page 30 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications ............3-2 Table of Contents ............ 3-4 Back to TOC...
  • Page 31 (0.0012-0.0024 in.) removed from the frame. Valve Guide/ (max) 0.35 mm (0.014 in.) Stem Deflection NOTE: Arctic Cat recommends the use of new (wobble deflection) gaskets, lock nuts, and seals and lubricating all Valve Guide Inside Diameter 5.500-5.512 mm internal...
  • Page 32 CYLINDER, PISTON, AND RINGS CLUTCH Piston Skirt/Cylinder (max) 0.12 mm (0.0047 in.) Clutch Release Screw 1/8 turn back Clearance Drive Plate (fiber) (min) 2.4 mm (0.094 in.) Cylinder Bore (max) 66.09 mm (2.602 in.) Thickness Piston Diameter 65.880 mm (2.5936 in.) Drive Plate (fiber) (min) 11 mm (0.43 in.) 18 mm (0.71 in.) from Skirt End...
  • Page 33 ! WARNING Table of Contents Battery acid is harmful if it contacts eyes, skin, or clothing. Care must be taken whenever handling a battery. Removing Engine/Transmission......3-4 Top-Side Components........... 3-10 3. Remove the reinstallable rivet from the bottom Removing Top-Side Components ......3-10 of the electrical tray;...
  • Page 34 KM324A KM106A 12. Remove the starter positive wire; then remove 14. Loosen the clamps; then remove the front and the engine ground wire. rear V-belt cooling boots from the V-belt hous- ing. KM319A 13. Drain the coolant, engine oil, and transmission KM359A gear lubricant;...
  • Page 35 KM314 KM332 16. Remove the output drive sprocket cover; then 20. Raise the engine lift to take the slack out of the remove the output drive sprocket. sling; then remove the upper rear and lower rear engine through-bolts. KM344A 17. Disconnect the shift linkage from the transmis- KM333A sion shift arm.
  • Page 36 KM330 KM314A KM331 KM314B Utility Model 1. Remove the seat; then remove the battery box cover. KM106A 4. Remove the gas tank cover panel and gas tank vent hose. 5. Remove the side panels; then remove the front rack and front fenders (see Section 8). KM133A 2.
  • Page 37 KM347A KM360A KM324A KM323 12. Remove the starter positive wire; then remove the engine ground wire from the crankcase. KM314 14. Loosen the output drive boot clamp; then slide the boot off the output housing. KM319A 13. Remove the front and rear V-belt cooling boots from the V-belt housing;...
  • Page 38 16. Remove the front engine through-bolt; then remove the two engine mounting brackets from the frame. KM325A 19. Swing the rear of the engine/transmission to the left; then slide the engine out of the left-side of the frame. KM414A 17. Attach a suitable lifting sling and engine lift to the front engine mounting boss;...

  • Page 39: Top-Side Components

    B. Cylinder Head NOTE: Remove the spark plug and timing inspection plug; then rotate the crankshaft to top-dead-center of the compression stroke. NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all KM706A internal...
  • Page 40 7. Using a needle nose pliers, remove one piston pin circlip. Take care not to drop it into the crankcase. KM718A 6. Remove the cam chain guide; then disconnect the coolant hose and remove the cylinder. Sup- port the piston with rubber bands or other suit- able supports.

  • Page 41: Left-Side Components

    Left-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. AT THIS POINT KM253 3. On the Utility model using a suitable holder to To service any one specific component, only limited prevent the drive pulley from turning, remove disassembly of components may be necessary.

  • Page 42: Right-Side Components

    KM369 KM106 6. Remove the drive pulley collar and the movable 2. Remove the drive sprocket cover; then remove drive face taking care not to loose the rollers. the cap screws and lock plate securing the sprocket to the driveshaft and remove the sprocket.
  • Page 43 KM611A KM620A 5. Remove the shift shaft; then remove the plug. Account for one shift cam stopper ball, spring, and seal/washer. KM621 7. Remove the shift fork; then remove the main shaft assembly. KM677A KM622A 8. Remove the countershaft; then remove the pri- KM619A 6.
  • Page 44 A. Transmission (Utility Model) 1. Drain the transmission lubricant into a suitable container; then install the drain plug and tighten to specifications. KM649 5. Using a Spanner Wrench (p/n 0444-153) to hold the centrifugal clutch housing, remove the nut securing the secondary drive bevel gear to the driveshaft.
  • Page 45 KM652A KM680 7. Remove the shift shaft; then remove plug, 10. Remove the countershaft and driveshaft as an seal/washer, spring, and shift cam stopper ball. assembly. KM677A KM681 11. To disassemble the countershaft, use the follow- ing procedure. A. Remove the thrust washer and high gear clutch dog.
  • Page 46 KM685 KM692A 12. To disassemble the driveshaft, use the following 13. To disassemble the secondary driven bevel gear procedure. assembly, use the following procedure. A. Remove the thrust washer; then remove the A. Secure the universal joint using a suitable reverse gear.
  • Page 47 B. Water Pump C. Stator Coil D. Trigger Coil E. Rotor/Flywheel AT THIS POINT To remove/service the water pump, see section 4. 9. Remove the right crankcase cover (see Section 4 - Water Pump). 10. Remove the trigger coil mounting screws; then KM775 remove the wire set plate.

  • Page 48: Center Crankcase Components

    18. Remove the two cap screws securing the oil pump to the crankcase and remove the oil pump. Center Crankcase Components NOTE: This procedure cannot be done with the engine/transmission frame. Complete Removing procedures for Top-Side, Left-Side, and Right-Side must precede this procedure. KM767A NOTE: For efficiency, it is preferable to remove and disassemble only those components which...

  • Page 49: Disassembling Crankcase Half

    Disassembling Table of Contents Crankcase Half (Servicing Components) NOTE: Critical engine/transmission specifica- 1. Remove the crankshaft from the left crankcase tions are located at the beginning of this section. half. Servicing Top-Side Components ......3-20 Valve Assembly ..........3-20 Cylinder Head Assembly........3-22 Piston Assembly ..........
  • Page 50 2. Remove the valve seal, valve springs, and the lower remaining spring seat. Discard the valve seal. NOTE: The valve seals must be replaced. 3. Invert the cylinder head and remove the valves. KM708A 2. Inspect the camshaft holder for cracks, distor- tion, or galling.

  • Page 51: Cylinder Head Assembly

    Measuring Valve Guide Measuring Cylinder Head (Inside Diameter) Distortion 1. Insert a snap gauge 1/2 way down into each 1. Remove any carbon buildup in the combustion valve guide bore; then remove the gauge and chamber. measure it with a micrometer. 2.

  • Page 52: Piston Assembly

    Measuring Camshaft Lobe Height 1. Using a calipers, measure each cam lobe height. ATV-1011A 4. Place a spring retainer over the valve springs; then using the valve spring compressor, com- press the valve springs and install the valve cot- ters. ATV1013A 2.
  • Page 53 Removing Piston Rings 1. Starting with the top ring, slide one end of the ring out of the ring-groove. KM452 Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore 1. Measure the piston pin outside diameter at each CC400D 2. Remove each ring by working it toward the end and in the center.

  • Page 54: Cylinder Assembly

    Measuring Piston Skirt/ Cylinder Clearance 1. Measure the cylinder front to back in six places. 726-306A ! CAUTION Incorrect installation of the piston rings will result in engine damage. CC397D 2. Measure the corresponding piston diameter at a CYLINDER ASSEMBLY point 15 mm (0.6 in.) above the piston skirt at a right angle to the piston-pin bore.

  • Page 55: Servicing Left-Side Components

    Honing Cylinder Servicing Left-Side 1. Using a slide gauge and a dial indicator or a Components snap gauge, measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90° from the first mea- surements for a total of six measurements.
  • Page 56 6. Remove the spiral spring from the case by lift- ing the spring end up and out. Hold the remain- der of the spring with thumbs and alternately release each thumb to allow the spring to gradu- ally release from the case. 7.
  • Page 57 3. Apply low-temperature grease to the spring and hub. 4. Thread the end of the rope through the guide hole of the case; then thread the rope through the handle and washer and secure it with a double knot. Install the protective cover into the handle. KM397A 7.

  • Page 58: V-Belt Cover

    KM412 KM256 2. Inspect the face surfaces of the fixed and mov- NOTE: Increasing the rotations in step 10 will able drive faces for grooving, nicks, or discolor- increase spring tension. ation. 12. Place the recoil starter assembly into position on the left-side cover;...

  • Page 59: Driven Pulley/Centrifugal Clutch Assembly

    DRIVEN PULLEY/CENTRIFUGAL CLUTCH ASSEMBLY Disassembling ! WARNING This procedure involves relaxing a compressed spring assembly. DO NOT attempt disassembling without the proper tools. 1. Place the driven pulley on a suitable spring com- pressor; then mark the pulley faces and centrifu- KM375 gal clutch for alignment during assembling.
  • Page 60 Inspecting 1. Inspect the pulley faces for wear, galling, or grooving. KM382A 4. Inspect the pins and bushings for wear, flat spots, looseness, or cracking. KM394A 2. Inspect the O-rings on the movable face for nicks, tears, or swelling. KM379 5.
  • Page 61 3. Install the pins and spacers into the fixed face hub; then pack the cam slots in the movable face with multi-purpose grease. KM378 7. Measure the thickness of the centrifugal clutch shoe lining. The minimum service limit for the lining is 0.5 mm (0.020 in.).

  • Page 62: Servicing Center Crankcase Components

    2. Zero the indicator and push the small end of the connecting rod away from the dial indicator. 3. Maximum deflection must not exceed specifica- tions. Measuring Connecting Rod (Big End Side-to-Side) 1. Push the lower end of the connecting rod to one side of the crankshaft journal.

  • Page 63: Crank Balancer Shaft

    3. Zero the indicator and rotate the crankshaft slowly. Servicing Right-Side Components ! CAUTION Care should be taken to support the connecting rod when rotating the crankshaft. NOTE: Whenever a part is worn excessively, 4. Maximum runout must not exceed specifica- cracked, damaged in any way, or out of tolerance, tions.
  • Page 64 2. Install the clutch dog, splined washer, bushing, and primary driven gear onto the main shaft; then install the second splined washer, spacer collar, and thrust washer. The main shaft is now assembled and can be installed. KM626 5. Inspect all gear teeth for chipping, discoloration, pitting, or excessive wear.

  • Page 65: Transmission (Utility Model)

    KM613A KM623 6. Install the shift shaft making sure the pin in the 2. Inspect the shift forks for distortion, discolora- gear position switch engages the slot in the shift tion, or excessive wear. shaft and the shift shaft gear is correctly timed to the shift cam.
  • Page 66 8. Inspect transmission housing and cover for cracks, scoring or galling of bearing bores, or case discoloration. 9. Inspect the drive and driven bevel gears for chipping, flaking, or excessive wear in the splines. Replace as required. KM696 2. Replace any required bearings and seals in the secondary driven bevel gear shaft case.
  • Page 67 KM425 KM684 5. Use a center punch to stake the nut to the driven 8. Install the low driven gear washer on the drive- shaft. shaft; then install the low driven gear and thrust washer. Secure with a circlip. KM426A 6.
  • Page 68 KM699 KM702A 11. Install the low/reverse shift fork into the 15. Install the two alignment pins, gasket, and trans- low/reverse clutch dog; then install the shift cam mission case cover and secure with eight cap into the transmission case and engage the shift screws.

  • Page 69: Assembling Crankcase Half

    KM673 KM728A 19. Loosely secure the secondary driven bevel gear assembly using the four cap screws; then using a Joining Crankcase crisscross pattern, tighten the cap screws until fully seated in the transmission housing. Tighten Halves to specifications. 1. Verify that the alignment pins and a new gasket are in place and that both case halves are clean and grease free.

  • Page 70: Installing Right-Side Components

    B. Rotor/Flywheel C. Trigger Coil D. Stator Coil 4. Install the starter idler shaft and gear in the crankcase; then install the starter driven gear oil on the crankshaft. CC871 5. In a crisscross/case-to-case pattern, tighten the cap screws until the halves are correctly joined; then tighten to specifications.

  • Page 71: Installing Left-Side Components

    Installing Left-Side Components A. Drive Pulley B. Driven Pulley/Centrifugal Clutch Assembly C. V-Belt Cover 1. Install the movable drive face and drive pulley collar on the crankshaft. KM263A 5. On the Utility model, install the starter ratchet on the crankshaft making sure to engage the 2.

  • Page 72: Installing Top-Side Components

    KM253 ATV-1085B NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation. B. Install the compression rings (1 and 2) so the letter on the top surface of each ring faces the dome of the piston.
  • Page 73 3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing; then remove the piston holder and seat the cylinder firmly on the crankcase.

  • Page 74: Installing Engine/Transmission

    KM707A KM703 Installing Engine/Transmission DVX Model NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the ATV. KM706A 1. Attach a suitable engine lift to the front engine 10. Install the cam chain tensioner assembly and mounting boss;...
  • Page 75 V-belt housing and secure with the clamps. Utility Model Tighten securely. 12. Connect the starter wire to the starter stud and NOTE: Arctic Cat recommends that new gaskets secure with a washer and nut. Tighten securely. and O-rings be installed whenever servicing the ATV.
  • Page 76 KM328 KM315A 3. Slide the engine/transmission rearward into the 9. Connect the V-belt cooling boots to the V-belt rear engine mounts; then install the rear housing and secure with the existing hose through-bolts and nuts. Do not tighten at this clamps.
  • Page 77 12. Install the coil (see Section 5). 13. Install the carburetor (see Section 4). 14. Install the muffler assembly (see Section 8). 15. Install the gas tank (see Section 4). 16. Install the air filter (see Section 4). 17. Install the fenders and front rack; then install the side panels (see Section 8).
  • Page 78 SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Carburetor Specifications ........4-2 Carburetor Schematic ..........4-2 Carburetor ............... 4-3 Cleaning and Inspecting Carburetor......4-5 Throttle Cable Free-Play ......... 4-6 Engine RPM (Idle)........... 4-6 Gas Tank ..............4-6 Gas Tank Valve ............4-7 Gas/Vent Hoses .............

  • Page 79: Carburetor Specifications

    Carburetor Specifications DVX Model Utility Model Type Keihin PTG-22 Type Keihin PTG-22 Main Jet Main Jet Slow Jet Slow Jet Pilot Screw Setting (turns) 1 1/2 Pilot Screw Setting (turns) 1 1/2 Needle Jet 3.6/2.5 Needle Jet 3.6/2.5 Jet Needle NBSD-3 Jet Needle NBSD-3...

  • Page 80: Carburetor

    DISASSEMBLING Carburetor 1. Remove the Phillips-head screws securing the float chamber; then remove the chamber. Account for the O-ring. ! WARNING Whenever any maintenance or inspection is per- formed on the fuel system during which there may be fuel leakage, there should be no welding, smok- ing, open flames, etc., in the area.
  • Page 81 KM438A KM443A NOTE: Note the locations of the jets, pilot screw, ASSEMBLING and needle jet holder for disassembling proce- dures. 1. Thread the idle screw into the carburetor making sure the spring is properly positioned. 2. Install the pilot screw with spring, washer, and O-ring.

  • Page 82: Cleaning And Inspecting Carburetor

    3. Position the carburetor in the air cleaner boot and intake pipe assembly; then secure with the clamps. 4. Connect the hose at the gas tank valve connec- tion. 5. As necessary, secure the air-intake snorkel, the air cleaner housing cover, or the air cleaner housing.

  • Page 83: Throttle Cable Free-Play

    9. Inspect tips of the jet needle, pilot screw, and the inlet needle valve for wear, damage, or distor- tion. 10. Inspect the slow jet and main jet for obstructions or damage. NOTE: If the slow jet is obstructed, the mixture will be extremely lean at idle and part-throttle oper- ation.

  • Page 84: Gas Tank Valve

    Gas Tank Valve Gas/Vent Hoses The ATV has a valve attached to the gas tank. There Replace the gas hose every two years. Damage from are three positions: ON, RES, and OFF. aging may not always be visible. Do not bend or obstruct the routing of the carburetor vent hose.

  • Page 85: Liquid Cooling System

    CLEANING AND INSPECTING REMOVING 1. Drain the coolant at the engine. NOTE: If any part is worn excessively, cracked, or damaged in any way, the oil pump must be replaced. 1. Clean all oil pump components. 2. Inspect the rotors for scoring and gouges. 3.

  • Page 86: Hoses/Thermostat

    4. On the Utility model, install the front cover and INSPECTING fender assembly; then install the front rack (see Section 8). NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is 5. Fill the cooling system with the recommended necessary.

  • Page 87: Water Pump

    2. Inspect the mechanical seal and pump drive seal for damage. Water Pump NOTE: If the mechanical seal and/or pump drive seal are damaged, they must be replaced as a set. REMOVING/DISASSEMBLING 3. Inspect the impeller for corrosion or damage. 1.
  • Page 88 SECTION 5 - ELECTRICAL SYSTEM TABLE OF CONTENTS Specifications ............5-2 Battery..............5-2 RPM Limiter ............5-2 Testing Electrical Components........ 5-2 Brakelight Switch (Auxiliary)........5-2 Brakelight Switch (Handlebar Control) ....5-3 Coolant Temperature and Cooling Fan Switches ..5-3 Fan Motor ..............5-4 Fuse Block...............

  • Page 89: Specifications

    Specifications Testing Electrical Components IGNITION All of the electrical tests should be made using the Ignition Timing 5° BTDC (“F” mark) @1000 Fluke Model 73 Multimeter (p/n 0644-191) and when testing peak voltage, the Peak Voltage Read- Spark Plug Type NGK DPR7EA-9 ing Adapter (p/n 0644-307) must be used.

  • Page 90: Brakelight Switch (Handlebar Control)

    RESISTANCE (Switch Connector) RESISTANCE (Switch) ! CAUTION ! CAUTION Always disconnect the battery when performing Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. resistance tests to avoid damaging the multimeter. 1. Set the meter selector to the OHMS position. NOTE: The brake lever must be compressed for this test.

  • Page 91: Fan Motor

    4. Allow the water to cool. On the cooling fan NOTE: To determine if the fan motor is good, switch when the temperature is within a range of connect the blue wire from the fan connector to a 80-85° C (176-185° F), the meter should read an 12 volt DC power supply;...

  • Page 92: Fuses

    PEAK VOLTAGE (Primary/CDI Side) NOTE: Battery voltage will be indicated from only one side of the fuse holder connector termi- NOTE: All of the peak voltage tests should be nal; the other side will show no voltage. made using the Fluke Model 73 Multimeter (p/n NOTE: If the meter shows no battery voltage, 0644-191) with Peak Voltage Reading Adapter (p/n troubleshoot the battery, fuse block, or the main...

  • Page 93: Indicator Lights (Dvx Model)

    Spark Plug Cap TESTING 1. Connect the red tester lead to one end of the cap; NOTE: If any functions (segments or displays) then connect the black tester lead to the other are not normal or do not display as indicated, the end of the cap.

  • Page 94: Ignition Switch

    8. Connect the red MaxiClip to the blue wire; then connect a voltmeter to the MaxiClips (red meter Ignition Switch lead to red and black meter lead to black). 9. Set the meter selector to the DC Voltage posi- tion; then turn the ignition switch to the The connector is the white one beneath the front LIGHTS position and the light control switch to cover.

  • Page 95: Handlebar Control Switches

    NOTE: If the meter does not show as specified, replace the switch/component or connector. Handlebar Control Switches RESISTANCE (Emergency Stop) 1. Set the meter selector to the OHMS position. Two white connectors join the handlebar control 2. Connect the red tester lead to the brown/blue switch pigtails to the main harness.

  • Page 96: Starter Motor

    VOLTAGE (Stator Coil - No Load) NOTE: The battery must be at full charge for these tests. The connector is the black and white one on the right side of the engine just above the brake cable Stator Coil (Trigger) adjuster.

  • Page 97: Cdi Unit

    NOTE: Prior to replacing the CDI unit to assure the CDI unit is defective, it is advisable to perform a CDI peak voltage test (see Ignition Coil in this section) and/or perform a continuity test of the wir- ing harness from the CDI connector to the CDI unit.

  • Page 98: Headlights

    NOTE: The brakelight should illuminate when- ever either brake is applied. If the brakelight does Headlights not illuminate, troubleshoot the respective brake- light switch. 2. Apply the opposite brake from step 1. There On the Utility model, the connectors are the two should be an audible “click”...

  • Page 99: Ignition Timing

    1. Set the meter selector to the DC Voltage posi- 2. Connect the red tester lead to the green/yellow tion. wire; then connect the black tester lead to the green wire. 2. Connect the red tester lead to the brown/black wire;...

  • Page 100: General Information

    SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 General Information..........6-2 Rear Drive Assembly Schematics ......6-2 Rear Drive Axle (DVX Model)........6-2 Rear Drive Axle (Utility Model) ........ 6-6 Back to TOC...
  • Page 101 Utility Model Drive System NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions. NOTE: Critical torque specifications are located in Section 10. General Information KM463 Rear Drive Axle SPECIAL TORQUE WRENCH (DVX Model) ADAPTER...
  • Page 102 KM471 KM481 6. Remove the brake disc assembly from the axle. 9. Remove the brake caliper holder and aligning collar. Account for the O-ring. KM472 7. Loosen the drive chain (see Section 2); then slip KM483 the chain off the sprocket and remove the axle 10.
  • Page 103 NOTE: If the axle bearings are replaced, replace the dust seals with new ones. Always pack the bearings with a good quality wheel bearing grease. Removing Bearings 1. Remove the dust seals using an appropriate seal removal tool; then using an appropriate driver, drive the bearings out of the axle housing.
  • Page 104 NOTE: To aid in tightening the axle nuts, engage the brake lever lock. NOTE: It is necessary to calculate the torque value using the following formula due to the offset of the special tool used to tighten the axle nuts. 6.

  • Page 105: Rear Drive Axle

    KM470 KM505 8. Adjust the drive chain (see Section 2); then 5. Remove the rear drive gear case; then drain the tighten the two cap screws. gear case. 9. Install the wheel hubs and tighten the rear wheel 6. Loosen the clamp securing the joint boot to the hub nuts to specifications;...
  • Page 106 KM506 KM509 9. From the left side, remove the pivot lock nut 12. Remove the eight cap screws securing the swing using Pivot Lock Nut Wrench (p/n 0444-201); arm to the final drive gear case. then remove the left pivot adjusting bolt. KM513 13.
  • Page 107 14. Place the right end (shorter length) of the axle on a wood block; then using a rubber mallet, drive the gear case from the axle. KM539 KM538 ! CAUTION Support the gear case by hand or damage to the gear case could occur as it will fall free once it clears the splined portion of the axle.
  • Page 108 REPLACING SWING ARM SEALS 4. Using a suitable bearing driver, install the new axle bearing into the axle housing; then install AND BEARINGS the O-ring and dust plate. Tighten the three cap screws securely. To replace damaged or worn seals and bearings in the swing arm assembly, use the following proce- INSTALLING dure.
  • Page 109 7. Install the right pivot bolt and left pivot adjust- NOTE: Apply a liberal amount of grease to the ing bolt and tighten securely; then move the driveshaft splines and the driveshaft spring. This swing arm up and down to seat the bearings. will aid in keeping the spring in position while Tighten the left and right pivot bolts to specifi- assembling.
  • Page 110 11. Pour the recommended gear lubricant into the 14. Install the hub nuts and tighten to specifications; fill hole until lubricant is visible on the threads then install new cotter pins and bend as shown. of the level hole; then install the level plug and the fill plug and tighten to specifications.
  • Page 111 SECTION 7 - SUSPENSION TABLE OF CONTENTS Front and Rear Suspension Assembly Schematics............. 7-2 Front Shock Absorbers..........7-2 Rear Shock Absorber ..........7-3 Swing Arm............... 7-4 Front A-Arms ............7-7 Wheels and Tires ..........7-10 Back to TOC...

  • Page 112: Front And Rear Suspension Assembly Schematics

    Front and Rear Front Shock Absorbers Suspension Assembly Schematics NOTE: Critical torque specifications are located in Section 10. REMOVING 1. Secure the ATV on a support stand to elevate the wheels and to release load on the suspension. ! WARNING Make sure the ATV is solidly supported on the sup- port stand to avoid injury.

  • Page 113: Rear Shock Absorber

    INSTALLING 1. Install each shock absorber to the frame and A-arm with cap screws and nuts. Tighten all nuts to specifications. ! CAUTION Do not tighten the nut beyond the recommended specification or the shock eyelet or mount WILL be damaged.

  • Page 114: Swing Arm

    INSTALLING 2. Remove the rear wheels; then remove the rear hub caps and hub nuts. Discard the cotter pins. 1. Raise the swing-arm and place the shock 3. Remove the rear axle assembly (see Section 6); absorber in position; then install the upper and then remove the rear shock absorber.
  • Page 115 2. To inspect the swing arm and swing arm axle, place the swing arm axle and bushings in the swing arm; then using the flange bolt, rock the bushings and axle from side to side and up and down. If excessive play is noted, the bushings, axle, or swing arm must be replaced.
  • Page 116 3. Using an appropriate seal driver, install the new dust seals in the cushion arm; then apply multi-purpose grease to the bearings, bushing, and dust seal lips. 4. Install the bushings in the cushion arm and cush- ion link; then connect the cushion link to the cushion arm with the flange cap screw and lock nut.

  • Page 117: Front A-Arms

    8. Place the cushion arm and cushion arm/link assembly into position and secure with the flange cap screws and new lock nuts. Tighten to specifications. KM469 KM557A 9. Install the shock absorber and secure with the existing hardware. Tighten to specifications. 10.
  • Page 118 SP366 KM573 3. Remove the nut securing the hub. 7. Remove the brake hose clamp from the A-arm; then remove the cotter pins and slotted nuts 4. Remove the cap screws securing the brake cali- securing the upper and lower ball joints. per;...
  • Page 119 NOTE: The pivots are equipped with roller bear- ings. The bearing rollers may fall out when the spacers are removed. 5. Check the bearings for excessive wear and replace them if worn. 6. Using a suitable bearing remover, remove the pivot bearings;...

  • Page 120: Wheels And Tires

    TIRE SIZE solvent. ! WARNING 2. Clean the tires with soap and water. Use only Arctic Cat approved tires when replacing 3. Inspect each wheel for cracks, dents, or bends. tires. Failure to do so could result in unstable ATV operation.
  • Page 121 2. Inspect the tires for damage, wear, or punctures. ! WARNING Do not operate the ATV if tire damage exists. NOTE: If repair is needed, follow the instructions found on the tire repair kit or remove the wheel and have it repaired professionally. NOTE: Make sure all tires are the specified size and have identical tread pattern.
  • Page 122 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering Post/Tie Rods ........... 8-2 Measuring/Adjusting Toe-In/Toe-Out ....... 8-4 Body ................ 8-4 Steering Post Cover/Instrument Pod ....... 8-7 Back to TOC...

  • Page 123: Steering Post/Tie Rods

    Steering Post/ Tie Rods NOTE: Critical torque specifications are located in Section 10. KM590 5. Remove the cotter pin and slotted nut from the lower end of the steering post; then remove the upper steering shaft support block. Account for a cable guide, two steering support blocks, and the upper steering post bushing.
  • Page 124 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Wash the tie rod ends in parts-cleaning solvent. Dry with compressed air. Inspect the pivot area for wear. Apply a low-temperature grease to the ends.

  • Page 125: Measuring/Adjusting Toe-In/Toe-Out

    2. Support the front of the ATV with the wheels free to rotate; then center and secure the handle- bar. 3. Measure the distance (A) and (B) between the front wheels; then subtract distance (B) from (A). Distance A - Distance B = Toe-In. KM590 5.
  • Page 126 SP107 KM785A 2. Remove the CDI, start-in-gear relay, and fuse block and lay aside without disconnecting the wires; then remove the shift knob. 3. Remove the six cap screws securing the body to the top of the frame; then remove the cap screws from the bottom of the battery box.
  • Page 127 KM793A KM799B 2. Disconnect the negative battery cable first; then 7. Disconnect the left and right headlight connec- the positive cable. tors; then disconnect the taillight. 3. Remove the battery hold-down strap; then 8. Remove the gas tank cover; then remove the remove the battery.

  • Page 128: Steering Post Cover/Instrument Pod

    4. Install the six cap screws securing the body to the top of the frame. Tighten securely. 5. Install the fuse block, start-in-gear relay, and the CDI; then install the body mounting cap screw into the bottom of the battery box. 6.
  • Page 129 INSPECTING/SERVICING INSTALLING (DVX Model) (DVX Model) 1. Connect the indicator lamp connectors; then connect the main harness connector to the igni- 1. Remove the two self-tapping screws securing tion switch. the indicator lamp assembly in the steering post cover. 2. Place the steering post cover onto the mounting bracket;...
  • Page 130 SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Front Brake Lever/Master Cylinder Assembly ..9-2 Auxiliary Brake Pedal/Master Cylinder Assembly..9-3 Throttle Control ............9-4 Back to TOC...
  • Page 131 3. Remove the brake lever, brakelight switch, and brake lever lock. Front Brake Lever/ Master Cylinder INSPECTING Assembly NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. NOTE: Critical torque specifications are located 1.

  • Page 132: Auxiliary Brake

    2. Compress the reservoir clamp and remove the reservoir hose; then remove the union bolt. Account for and discard two crush washers. KM800B 4. Using new crush washers, secure the brakeline hose to the master cylinder with the brakeline hose union bolt. Tighten to specifications. KM801A 3.

  • Page 133: Throttle Control

    2. Remove the three machine screws securing the cover to the throttle control; then remove the cover and disengage the throttle cable from the throttle arm. 3. Turn the cable adjuster out of the throttle control housing; then remove the two machine screws securing the throttle control to the handlebar and remove the throttle control.
  • Page 134 SECTION 10 - AIDS FOR MAINTENANCE TABLE OF CONTENTS Torque Specifications (Utility Model) ..... 10-2 Torque Specifications (DVX Model)....... 10-3 Torque Conversions ..........10-4 Tightening Torque (General Bolts) ......10-4 10-1 Back to TOC...

  • Page 135: Engine/Transmission

    Torque Specifications (Utility Model) DRIVE TRAIN COMPONENTS SUSPENSION COMPONENTS (Front) Torque Torque Part Part Bolted To Part Part Bolted To kg-m ft-lb kg-m ft-lb Engine Mounting Bolt Frame 29.0 A-Arm Pivot Nut Frame 32.0 Engine Mounting Bracket Frame 16.0 Front Shock Absorber Frame 29.0 Cap Screw...

  • Page 136: Torque Specifications

    Torque Specifications (DVX Model) DRIVE TRAIN COMPONENTS SUSPENSION COMPONENTS (Front) Torque Torque Part Part Bolted To Part Part Bolted To kg-m ft-lb kg-m ft-lb Engine Mounting Bolt Frame 29.0 A-Arm Pivot Nut Frame 32.0 Engine Mounting Bracket Frame 16.0 Front Shock Absorber Frame 29.0 Cap Screw...
  • Page 137 Torque Conversions ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m 11.2 11.3 11.5 11.6 11.8 11.9 12.0 12.2 12.3 12.5 12.6 10.0 12.8 10.1 12.9 10.2 13.0 10.4 13.1 10.5 13.3 10.7 13.4 10.8 13.6 10.9 13.7 11.1 13.8 Tightening Torque (General Bolts)
  • Page 138 SECTION 11 - TROUBLESHOOTING TABLE OF CONTENTS Engine ..............11-2 Drive ..............11-5 Fuel System ............11-5 Electrical..............11-6 Steering/Suspension ..........11-8 Brakes ..............11-9 11-1 Back to TOC...

  • Page 139: Engine

    Engine Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn - seated poorly 2. Repair - replace guides 3. Valves mistimed 3.
  • Page 140 Problem: Engine noisy (Noise seems to come from crankshaft) Condition Remedy 1. Bearing worn - burned 1. Replace bearing 2. Lower rod-end bearing worn - burned 2. Replace bearing 3. Connecting rod side clearance too large 3. Replace thrust washer(s) Problem: Engine noisy (Noise seems to come from transmission) Condition Remedy...
  • Page 141 Problem: Engine runs poorly at high speed Condition Remedy 1. High RPM “cut out” against RPM limiter 1. Shift into higher gear - decrease speed 2. Valve springs weak 2. Replace springs 3. Valve timing out of adjustment 3. Adjust timing 4.

  • Page 142: Drive

    Drive Problem: Power not transmitted from engine to wheels Condition Remedy 1. Rear axle shaft serration worn - broken 1. Replace shaft Fuel System Problem: Starting impaired Condition Remedy 1. Starter jet obstructed 1. Clean jet 2. Starter jet passage obstructed 2.

  • Page 143: Electrical

    Electrical Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug defective 2. Replace plug 3. Magneto defective 3. Replace magneto 4. CDI unit defective 4. Replace CDI unit 5. Pick-up coil defective 5.

  • Page 144: Electrical System

    Problem: Starter button not effective Condition Remedy 1. Battery charge low 1. Recharge - replace battery 2. Switch contacts defective 2. Replace switch 3. Starter motor brushes not seating 3. Repair - replace brushes 4. Starter relay defective 4. Replace relay 5.

  • Page 145: Steering/Suspension

    Steering/Suspension Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Lubrication inadequate 2. Lubricate appropriate components 3. Tire inflation pressure incorrect 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.

  • Page 146: Brakes

    Problem: Rear wheel oscillation Condition Remedy 1. Rear wheel hub bearings worn - loose 1. Replace bearings 2. Tires defective - incorrect 2. Replace tires 3. Wheel rim distorted 3. Replace rim 4. Wheel hub cap screws loose 4. Tighten cap screws 5.

This manual is also suitable for:

Utility 250 2007

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